Volkswagen New Beetle. Manual - part 2531

Fig. 127: Checking 2nd Gear Synchro-Ring Inner Ring For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Press inner ring onto 2nd gear wheel cone and measure gap "a" with a feeler gauge. 

2ND GEAR SYNCHRO INNER RING GAP DIMENSIONS WEAR LIMIT 

Installation position synchro-ring (inner-ring) 

Gap "a"

New dimension

Wear limit

2nd gear

0.75 ... 1.25 mm

0.3 mm

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Fig. 128: Identifying Installation Position Synchro-Ring (Inner-Ring) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The lugs (arrow -1-) locate in the recesses (arrow -2-) in the synchro-ring -B-. 

Installation position 2nd gear wheel 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Fig. 129: Identifying Installation Position 2nd Gear Wheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The higher shoulder -A- faces to 1st gear -B-. The recesses in the shoulder (arrows) locate with the lugs of the 
outer-ring (arrow. See Installation position outer-ring ) 

Pressing on needle roller bearing sleeve for 3rd gear

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Fig. 130: Pressing On Needle Roller Bearing Sleeve For 3rd Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Disassembling and assembling 3rd and 4th gear locking collar and synchro-hub 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle